Continuous food processing system

ABSTRACT

A method and apparatus of continuously processing an elongated strand ( 1 ) of plastic edible material coated with a coagulated coating. A co-extruder ( 6 ) has interchangeable parts ( 9 B) to provide strands of varying diameter. The strand is conveyed through a closed tubular conveyor ( 106 ) through which a brine fluid is simultaneously passed. The drying of the strand includes an infrared drier ( 3 ). A linker and/or crimper ( 2 ) is provided.

This application is a continuation of application Ser. No. 08/722,163 filed Oct. 15, 1996, now U.S. Pat. No. 5,759,602 filed Jun. 2, 1998 which is a national stage entry of PCT/US94/11474 with an International filing date of Oct. 11, 1994.

BACKGROUND OF THE INVENTION

This invention relates to a continuous food processing system whereby an edible plastic food strand of meat or the like is co-extruded with a coated material to be processed into a casing. This coating material may consist of a mixture or gel with a coagulatable protein, and reinforcing means. More specifically this invention relates to a method for the manufacturing whereby the method includes the steps of co-extruding a principally equal layer of gel around an extruded edible product and the treatment of the extruded gel coating with chemical and physical means for coagulation.

Such a method is generally known. These known methods are mainly being used for the co-extrusion of sausage or sausage-like materials. In principal this method involves the extrusion of a cylindrical nucleus of a sausage mix and simultaneously the extrusion around the sausage mix of an outside coating which consists of a gel with a collagen protein. The proteins in the gel are coagulated with the aid of a coagulation means.

The term “coagulation” is a term of art in the production of collagen coated sausage material and is not strictly scientific in the sense in which it is used. Coagulation as it is used in this specification refers to the step involving hardening and stabilization of the casing. This is principally achieved in two ways; firstly by removal of water from the collagen gel, and secondly by cross-linking the collagen fibers.

In the generally known methods the water content gel coating is lowered with the assistance of osmosis by leading the strand of foodstuffs through a concentrated salt bath. Thereafter an air drying step is used to further enhance the strength of the sausage casing. After this treatment the mechanical properties of the casing are insufficient to allow for conventional twist linking, clipping, typing, or hanging of the foodstuff, i.e. sausage, strand. With this usual method it is habitual to crimp the co-extruded strand of foodstuff and cut it into independent elements and these elements are placed in a hot air dryer for the treatment of individual elements (for example drying, smoking etc.)

This known method has a number of disadvantages. The first disadvantage is that a sausage is manufactured in which the organoleptical properties are insufficiently equal to sausage which has been manufactured with a natural or artificial casing which are known in the trade. A second disadvantage is that the method limits itself to the manufacturing of smoked/cooked sausage and fresh sausage. Dried semi-dried and fresh sausage cannot be economically manufactured. A third disadvantage is that usual smoke-and/or cooking installations cannot be used economically in the further processing. With the known method the meat mix is provided with a collagen coverage while with the traditional methods a casing is used which strongly and flexibly encloses the meat mix entirely during the further processing and shapes the sausage.

Further, a similar method is known from the international patent application WO93/12660 whereby it is intended to avoid the aforementioned problems. This method equally includes the steps of coextruding a mainly equal layer of collagen gel around an extruded edible product and the chemical coagulation of the extruded collagen gel while using a chemical coagulation means, though without the step of drying with hot air in order to achieve a coagulated collagen casing around the edible product, which has sufficient strength to allow mechanical separation into individual foodstuff elements which are connected to each other, especially sausages.

Also, with this known method the aforementioned problems and disadvantages have not been resolved adequately. It has been demonstrated that a thus manufactured casing of collagen gel of co-extruded edible foodstuffs, i.e., sausages, has insufficient strength to allow traditional further processing. Furthermore a consequence of low casing strength is that the shape of the sausage rope is not consistent, principally in certain types of further processing. For instance, when strands of edible foodstuffs which are thus manufactured are being hung the partly “fluid” meat mix flows down which gives the edible foodstuffs a cone shape. Such a shape for sausages is undesirable. Additionally, due to the mechanical loading of the gel casing which is not strong enough rupture can occur. Also, the production speed with this known method is disadvantageously influenced by the still insufficient strength and shape rigidity of the casing. An additional disadvantage is that, due to the lengthy stay in the coagulation bath, the salt content in the casing and in the meat mix, is high. This results in unwanted organoleptical and physical changes of the sausage mix, such as in taste, consistency and firmness of the meat mix.

While this known method nevertheless has some attributes in spite of the above disadvantages, it is not capable of replicating the mechanical, physical and organoleptical properties of existing conventional sausages.

The principal purpose of the invention is a method for manufacturing of food strands with an edible casing in which the previous disadvantages of the known methods do not occur.

It is also the purpose of this invention to provide a novel linking method, advantageously used on continuous manufactured edible foodstuff strands, but can also be used in other sausage processing methods.

With the method according to the invention only the outside surface of the gel casing is being dried after the usual steps of co-extrusion and treatment with the coagulation means, by which moisture is being removed from the extruded gel, and the cross-linking of the collagen fibers is being facilitated, and thus the mechanical strength of the gel casing is increased. The strength which is achieved in this way is sufficient to provide a casing which can be further treated in the usual way. In the case of edible foodstuffs, i.e., sausage, manufacturing, it is possible to prepare in this way fresh smoked or cooked edible foodstuffs of which the properties are equal to those of known edible foodstuffs which have been manufactured in a natural or edible or non edible artificial casing.

The moisture content of the casing of the edible foodstuff after leaving the coagulation bath is approximately 90% or higher. With the drying of the outside surface of the gel casing the moisture content is lowered to a value whereby the casing will reach the desired mechanical strength. By adjusting the moisture content the mechanical strength of the casing can be adjusted to the desired value. Maximum strength of the casing can usually be achieved by lowering the moisture content to the range of 40-75%, for example, 50%.

The temperature of the meat under the casing will preferably stay low during the surface drying of certain types of sausages (for example below approximately 35 degrees C.) so that principally no coagulation of the food proteins such as meat proteins will occur. With other types of edible foodstuffs, the coagulation of the meat proteins can be desirable.

The drying of the surface of the formed casing can be effected with appropriate means. A device which is preferably being used for the drying is a surface dryer, whereby the casing is directly being irradiated by a radiation source whereby the moisture which is being removed out of the casing is being conducted away with the help of conditioned airflow. This conditioned airflow also prevents the sausage casing and the underlying meat mixture of being heated to unwanted temperatures. In this way a homogeneous drying of the casing is achieved down to for example 50% moisture in a short time of for example 30 seconds. An appropriate means of radiation is for example a source which emits middle wave infra red radiation.

Advantageously the method is provided with a separation step to separate the strand of foodstuffs into individual elements which are connected with each other. This can be effected in the usual way by crimping, twisting, clipping or tying before or after the surface drying of the strand of foodstuff which is provided with a casing.

In those places, where usually a twist, clip or such like is being used it is advantageous to isolate the individual elements with a chemical clip. In this application a chemical clip consists of a closure made up out of an edible or non-edible non-toxic material. Appropriate materials are for example, polyamide, polyethylene, cellulose and proteins and other natural or artificial polymers. Such a clip can for example occur by titrating, injecting, or spraying an appropriate quantity of an adequate material or materials so that in a short time by hardening a mechanical strong ring is being formed which holds the crimp during the following treatment steps of the strand of foodstuffs.

The invention also concerns a device for the manufacturing of strands of foodstuffs with a casing which is formed out of a protein, especially of sausage strands, which includes means for the co-extrusion of a principally homogeneous coating of gel around an edible product, as well as a coagulation bath for the chemical treatment of the extruded gel coating and transportation means for the transportation of the extruded strand of edible foodstuffs which is characterized in a surface dryer installed after the coagulation bath with a purpose of drying the gel casing.

Existing equipment and processes have other certain shortcomings. Among these shortcomings are extruders which are complex and cannot be easily adjusted so that the diameter of the food strand can be easily adjusted. Helical conveyors used for the strand are open and invite unwanted lateral movement of the strand during movement through the conveyer trough, and contamination is possible. Driers used are not highly efficient and are sometimes detrimental to the quality of the coating material.

It is therefore an object of this invention to provide a continuous food processing system that will permit an elongated strand of meat or the like to be coated with a coating material which is coagulated, crimped, dried, and conveyed in a rapid and efficient manner.

A further object of this invention is to provide an extruder which has a minimum number of parts and which can produce strands of different diameters.

A still further object of this invention is to provide an infrared drier to facilitate coagulation of the coating material.

A still further object of this invention is to provide an efficient crimping means for the coated strand which will not damage the coated edible strand.

A still further object of this invention is to provide a conveying system for an elongated strand of material that is sanitary and free from contamination.

These and other objects will be apparent to those skilled in the art.

The method for the manufacturing of foodstuff strands with a shaped casing of the aforementioned type according to the invention is characterized in fact that after the treatment with a chemical means moisture is being removed from the extruded gel casing through the drying of the exterior surface of the shaped gel casing.

SUMMARY OF THE INVENTION

A method and apparatus of continuously processing an elongated strand of plastic edible material coated with a coagulated coating. A co-extruder has interchangeable parts to provide strands of varying diameter. The strand is conveyed through a closed tubular conveyor through which a brine fluid is simultaneously passed. The drying of the strand includes an infrared drier. A linker and/or crimper is provided.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic flow diagram of the continuous meat processing system of this invention;

FIG. 1B is a top plan view of the apparatus of this invention;

FIG. 1C is a side elevational view as seen from the bottom of FIG. 1B;

FIG. 1D is an end elevational view as seen from the left hand end of FIG. 1C;

FIG. 1E is an end elevational view as seen from the right hand end of FIG. 1D;

FIG. 1F is an enlarged scale sectional view taken on line 1F—1F of FIG. 1B;

FIG. 2 is a longitudinal sectional view of the extruder of this invention;

FIG. 3 is an exploded view of the extruder showing interchangeable parts of the extruder to alter the size of the sausage diameter;

FIG. 4 is a flow diagram of the crimper and sealer of this invention;

FIG. 5 is a plan view of the pre-crimper of FIG. 4 shown at an enlarged scale;

FIG. 6 is an exploded view of the crimper of FIG. 4;

FIG. 6A is a sectional view taken on line 6A—6A of FIG. 6;

FIG. 7 is a side elevational view of the infrared drier;

FIG. 8 is an end elevational view of the right hand end of the infrared drier of FIG. 7; and

FIG. 9 is an enlarged detail view of FIG. 7 taken on line 9—9 of FIG. 8.

DESCRIPTION OF THE PREFERRED EMBODIMENT

The principal components of the system shown in FIG. 1 are as follows:

1. Meatbatter pump

2. Gel pump

3. Coagulant injection

4. Extruder

5. Salt bath

6. Washer

7. Air dryer

8. Portioner

9. Surface dryer

Features of the above components are set forth in the following Table I.

TABLE I Processing steps of the Continuous Casing Process. Nr. Description Variables Function Process-sequence 1 Meat batter 1 Comminuted and semi comminuted 1 To form the sausage rope with strong 2 Fat, water, protein content gelling and binding properties while 3 Other non meat additives optimizing yield 4 Temperature 0 to 18 degrees celsius 2 Gel 1 Kind of collagen 1 To coat the meat rope and to be 2 Percentage of collagen in gel manipulated in a continuous and 3 Percentage of non collagen additives edible casing f.i. C.M.C., caramel, etc. 4 PH 5 Temperature 2 to 18 degrees celsius 3 Coagulant 1 Kind and concentration of coagulant 1 To start crosslinking of the collagen injection 2 Percentage of injection v. collagen 2 To start coagulation of the collagen and 3 PH proteins of the meatbatter. 4 Percentage of salt 1 To deswell and dehydrate the collagen See process step 5 layer 4 Extruder 1 Revolution per minute f.i. from 50-300 1 To form a continuous rope of constant 2 Temperature 2 to 18 degrees celsius diameter and coated with a layer of 3 Diameter of the rope from 8 mm collagen gel of constant thickness f.i. onwards 0.5 mm 2 To orientate the fibres of the collagen gel to facillitate the cross linking. 5 Salt bath 1 Kind and percentage of salt 1 To deswell and dehydrate the collagen The salt bath may replace the salt 2 Temperature from 5 to 40 degrees C. layer injection via the coagulant injection or 3 Time from 2 up to 60 seconds 2 To allow time for coagulation of the visa versa collagen and the proteins of the meat 6 Washing 1 Water or a less concentrated solution 1 To reduce the percentage of salt in The washing may be eliminated of the salt and/or diluted sugar. the collagen layer 2 Temperature from 5-40 degrees C. 3 Time from 2 up to 60 sec. 7 Air dryer 1 Air flow 1 to remove water from the coating In the case the saltbath is eliminated 2 Air temperature 10 up to 40 degrees C. 2 To facillitate the strengthening of the by the coagulant injection, the 3 Time f.i. 0.5 to several minutes. casing positioning is directly after the extruder 8 Portioner & sealer 1. Pre- crimper 1 The shape of the meatpusher 1 To press the meat batter away from the 2 Rope speed, synchronised with the crimp location crimper 3 Crimper speed 2. Crimper 1 Crimp speed 1 To form the definite crimp 2 Rope speed synchronised with the pre- 2 To form the mold to shape the crimper polymer donut 3. Sealer 1 Kind of polymer f.i.; 1 To form a donut to hold the crimp For some sausages it is advantaguous non edible: polyamide, LDDE during further processing to use a heatseal instead of a donut edible: natural polymers crimp. The heatseal may be made 2 Temperature f.i. 120-230 degrees C. by means of ultrasonic heating 3 Time to cool of the polymer 9 Surface dryer 1 Radiation intensity 1 To strengthen the casing by heating the The surface dryer may replace the air the casing above shrinktemperature of dryer or vice versa the collagen gel, up to 80 degrees C. without coagulating the proteins of the meatbatter, if desired

The extruder 4 is best shown in FIGS. 2 and 3. The components of the extruder are as follows:

1B. Front plate

2B. Water seal

2B′. Bolt

3B. Outside planer

4B. Bolt

5B. Inner planer

6B. Bolt

7B. Flange

8B. Bolt

9B. Dual extruder tube

9B′. Horn

10B. Casing

11B. - - -

12B. Shaft

13B. Gears

14B. Cradle

15B. Tube

16B. (Arrow)

17B. - - -

18B. - - -

19B. Port

20B. Inlet end

FIG. 3 shows how members 1B, 3B, 5B and 9B can be removed from extruder 4. They can be replaced with similar components which have a different set of discharge orifices 100, 101, 102 and 103 to create a strand or rope 1E (FIG. 9) of varying diameters.

This is accomplished by removing bolt 8B to release flange 7B and dual extruding tube 9B from the tube 15B by moving the dual extruder tube 9B longitudinally to the left as viewed in FIG. 2. It should be noted that the discharge orifice 103 of dual extruder tube 9B as shown in FIG. 3 extends through the discharge orifice of outside planar 3B when assembled. The diameter of orifice 103 and the outlet end of horn 98′ are essentially the same. Thus, when a new dual extruder tube 9B having a different diameter orifice 103 is inserted in to tube 15B, it is also necessary for a different outside planar 3B having a different discharge orifice 101 to accommodate the new discharge orifice 103 on the new dual extruder tube 98′. This is accomplished by removing front plate 1B by removing bolts 2B′. (FIG. 2) Outside planer 3B is then removed by removing bolts 4B. Inner planer 5B is then removed by removing bolts 6B. Depending on the relative sizes of orifices 100, 101, 102 and 103, it may be that only outside planar 3B will have to be replaced to accommodate the new insert 9B. Normally, planars 3B and 5B would have to be replaced together to maintain the integrity of new passageway 16B to accommodate a new dual extruding tube 9B have an extruding horn 98B′ of a different diameter.

With reference to FIG. 2, the numeral 9B′ designates the meat emulsion stuffing horn having an inlet end 9B1 and an outlet end 99. The numeral 2B′ designates the bolts that hold end plate 2B to the housing 10B. In FIG. 3, the numerals 15B′ and 15B″ designate the inlet and outlet ends of the center tube 15B.

With reference to FIG. 2, casing 10B is stationary, shaft 12B and gears 13B rotate cradle 14B around tube 15B. Member 3B rotates in a direction opposite to member 5B. This causes the fibers in the coating gel to be oriented as the gel moves in the direction of arrow 16B between these two components to be coated on the meat strand exiting from orifice 103 on coextrusion horn 9B. A gel material mixed with a coagulation agent is introduced into horn 9B through port 19B. Meat emulsion or the like is introduced at 20B.

The collagen dough containing a cellulose ether (gel) and the meat batter are fed to the extruder by a stuffer with a constant volume frequency controlled motor. In the extruder the sausage batter and the collagen gel are extruded simultaneously, so that a continuous rope of sausage is formed with a collagen coating. An inner planar plate is rotatably mounted in the housing on the center tube adjacent the outlet end of the extruder, and an outside planar plate is rotatably mounted adjacent to the first inner planar place to create a narrow passageway connected to the first material passageway. The narrow passageway terminates in an orifice coextensive with the outlet end of the extrusion horn, wherein the outlet end of the extrusion horn dwells upstream from the end plate end within an outwardly flared portion of the orifice. The coextrusion of material extruded from the outlet end of the extrusion horn with material extruding from the narrow passageway takes place within the outwardly flared portion of the orifice upstream of an outer surface of the end plate.

The method of extruding comprises feeding under pressure the fluid of collagen fibrils (gel) into a passage way (see arrow 16B) between opposed planer surfaces, rotating said surfaces relative to each other to provide shearing forces to the collagen mass before extrusion. A frequency controlled electro motor provides the rotation of the planer surfaces in opposite senses at 60 to 125 rpm. The two planer surfaces constitute an extrusion die, the gap between them being 0.5 mm.

The lay out crimper and sealer 104 are shown in FIGS. 4 and 5. The component parts and function thereof are shown in the following Table II.

TABLE II Crimper and Sealer Nr. Description Function 0C Sausage rope — 1C Pendulum To adjust speed (to control the main drive on the crimp-seal machine). 2C Pre-crimper To force the meat batter away from the location of the crimp. 3C Turning wheel To guide the sausage rope. 4C Crimp-sealer To make the crimp by lowering the crimper into the support plate by means of a cam construction. To lower the dosing unit and to press the nozzle on to the crimper. To lift the dosing unit, nozzle and crimper after donut is formed. To set the length of the individual sausages (number of units on the wheel). 5C Dosing unit To inject an control the amount of polymer into the mould formed by the support plate and the crimper plate. In case of a heat seal, the dosing unit is replaced by a heating ele- ment f.i. a ultra sone welder. 6C Polymer Prepar- To mix and heat the ation tank. polymer.

The crimper 105 (FIG. 6) has the following components and functions:

TABLE III Crimper  1D Polymer inlet —  2D Connection — electricity  3D Dosing valve To dose and control the amount of polymer per donut (crimp)  4D Roller Guided by a circular cam construction to control the vertical movement.  5D Spring To press the nozzle away from the crimper.  6D Nozzle —  7D Crimper To make the crimp and to form a die for the donut.  7D′ Slot —  8D Support plate To support the sausage rope and form the contra part of the crimper.  9D Chain To transport the sausage rope 10D V-shaped notch To crimp strand 11D V-shaped notch — 12D Space

A frame (not shown) supports chain 9D to which is secured plate or die 8 which has a V-shaped groove 10D therein. The frame also supports elements 1D-7D. Crimper (die) 7 has an inverted V-shaped groove 11D therein and dwells in the same plane as die 8. Space 12D permits a strand of product to pass therethrough. Die 7D has notch 7D′ therein to receive die 8D. An adhesive or polymer deposits a donut-shaped quantity of adhesive in each crimp in the strand by action of 1D-6D.

The infrared drier is shown in FIGS. 7, 8 and 9, and has the following components and functions:

TABLE IV Infrared Drier Nr. Description Function 1E Sausage rope On support plates 2E Transport chain To carry the sausage rope through the dryer 3E Chain wheel To pull the chain 4E Power unit To provide a controlled speed 5E Ventilator To provide airflow for cooling the IR radiators and the surface of the sausage rope, and to transport the vaporized moisture 6E Air recirculation To control air ducts with regu- recirculation lation valves 7E Air inlet duct 8E Air pressure To divide the air over chamber the functional openings 9E Air exhaust To control the amount of ventilator circulation air 10E Support plate 11E IR radiator To provide the energy for vaporizing the moisture in the casing. 12E Reflection mirror To reflect the radiation energy for effective use on the sausaqe rope. 13E Opening for To control the cooling IR radiator temperature. 14E Opening for To control the rope cooling sausage temperature and to take rope away the vaporized moisture. 15E Restriction plate To provide overpressure in the drying zone. 16E Air recirculation chamber 17E Frequency control To regulate the frequency unit of the IR radiation 18E Arrows To indicate air flow 19E Arrows To indicate infrared radiation.

The arrows 18E indicates air flow, and the arrows 19E indicate infrared radiation.

FIGS. 1B-1E show the overall layout of the machine for processing the meat strand. Of particular importance is the serpentine (helix or spiral) tube 106 which receives the coated strand 1. The strand is conveyed by the brine through tube 106 to a depositing station 107. The tube is coiled horizontally, and a quantity of brine is flushed through tube 106 while the gel coated strand is floated downwardly therethrough to further assist in the curing and coagulation of the coating material. Because the interior of the tube is entirely closed, as compared to a U-shaped trough with an open top, contamination of the interior of the tube is avoided. (See FIG. 1F.)

Meat dough is introduced into the system at 108, and collagen dough (gel) is introduced into the system at 109.

From the foregoing it is seen that the device and method of this invention will accomplish at least all of the stated objectives. 

What is claimed is:
 1. An extruder for a coated edible strand of food product, comprising, a housing having a longitudinal center bore defined by the inner diameter of an elongated center tube having inlet and outlet ends, an elongated hollow dual extruder tube extending through the center bore and having an outer diameter less than an inner diameter of the center tube to create a space therebetween along the substantial length of the hollow dual extruder tube to create therebetween a first elongated material passageway, a material inlet port in the housing adjacent the inlet end of the elongated center tube and being connected to the first elongated material passageway for introducing a first material into the first elongated material passageway, a hollow extrusion horn having inner and outer diameters mounted in and extending longitudinally through the hollow dual extruder tube along the substantial length thereof and having an outer diameter less than an inner diameter of the hollow dual extruder tube to create a space therebetween, the extrusion horn having inlet and outlet ends adjacent the inlet and outlet ends, respectively, of the center tube, the hollow dual extruder tube being selectively slidably and detachably mounted in the center bore of the housing to permit it to be slidably inserted into and removed from the center bore, means on the hollow dual extruder tube for selectively fixedly mounting the hollow dual extruder tube and the extrusion horn within the center bore of the housing, an inner planar plate rotatably mounted in the housing on the center tube adjacent the outlet end thereof and extending around an outlet end of the hollow dual extruder tube, an outside planar plate rotatably mounted adjacent to the first inner planar plate to create a narrow passageway connected to the first material passageway, the narrow passageway terminating in an orifice coextensive with the outlet end of the extrusion horn, the outside planar plate rotatably mounted in the housing and forming the orifice of the narrow passageway adjacent to the outlet end of the extrusion horn to direct material flowing from the narrow passageway to be directed in a tangential direction parallel to an inner diameter surface of the extrusion horn to immediately deposit material from the narrow passageway to the surface of a sausage strand material as it is being discharged from the outlet end of the extrusion horn, means associated with the housing for rotating the inner and outer planar plates in opposite directions, the inner and outer planar plates being detachably secured to the housing for detachment therefrom and for the replacement thereof for substitute inner and outer planar plates to create a substitute narrow passageway to service a substitute hollow dual extruder tube having a diameter different than the extrusion horn mounted in the hollow dual extruder tube.
 2. The extruder of claim 1 wherein an end plate is secured to the outlet end of the housing and having the center bore concentric with the outlet end of the extrusion horn and the orifice of the narrow passageway whereby the center bore at the outlet end of the end plate dwells adjacent the orifice, and wherein the outlet end of the extrusion horn dwells upstream from the end plate end within an outwardly flared portion of the orifice, whereupon the coextrusion of material extruded from the outlet end of the extrusion horn with material extruding from the narrow passageway takes place within the outwardly flared portion of the orifice upstream of an outer surface of the end plate. 